Plastic net deck surface and drainage unit

ABSTRACT

A net, preferably an extruded plastic net, is used to provide a raised surface and drainage means for a sloped deck such as a ball field, patio, and the like.

United States Patent v UNITED STATES PATENTS 1 i I I Larsen 1 41 *Mar.5, 1974 [54] PLASTIC NET DECK SURFACE AND 572,762 12/1896 Landers 84/33x DRAINAGE UNIT 619,934 2/1899 Buchtel 94/33 X 1,594,261 7/1926Herschmann... 94/7 X [75] In ntor: R0na L- L n ap 2,023,307 12 1935Burton 94 7 x Minn. 2,240,240 4/1941 Brockman... 94/5 UX 4 2,345,3763/1944 Bodle 94/7 X [73] Assgneef Paul 3,025,772 3/1962 Palatini.... 944 Mlm ..j 2,360,674 10/1944 Harter 94/13 ,y 1 Notice: The p i f the termof Panm X Pawt May FOREIGN PATENTS OR APPLICATIONS has been dlsclaImed.1 848,118 9/1952 Gen'nany 94/33 [22] Filed: Feb. 26, 1969 [21] Appl.No.: 810,078 Primary Examiner-Jacob L. Nackenoff I Attorney, Agent, orFirm-Eyre, Mann &'Lucas [52] 11.8. C1 94/33, 94/4 94/7 i [51] Int. Cl.EO1c.11/24 57 ABSTRACT 58 Field of Se ch 94 4, 8, 33, 7, 5. 1 A net,preferably an extruded plastic net, Is used to [56] References Citedprovide a raised surface and drainage means for a sloped deck such as aball field, patio, and the like.

10 Claims, 14 Drawing Figures PATENTEDKAR 51914 3,795,180

SHEET 1 0F 2 INVENTOR. RONALD L. LARSEA/ H/s ATTORNEY PATENTED 3,795,180

SHEET 2 0f 2 FIG. .94

INVENTOR. RONALD L. LARSE/V 1'4/5 ATTORNEY PLASTIC NET DECK SURFACE ANDDRAINAGE UNIT Increasing use is being made of artificial surfacesoutdoors for tennis courts, baseball diamonds, and other like playingfields where water, from rain or otherwise, tends to make the naturalsurface of dirt, turf, and the like unplayable for considerable periodsof time.

Similarly, artificial surfaces are being used around swimming pools bothindoors and outdoors including such surfaces as the so-calledindoor-outdoor carpeting which utilizes synthetic fibers.

In all of these and like applications there is a problem of suchartificial surfaces retaining water when such surfaces are waterpenetrable as is commonly the case.

This invention is directed to an underlayment for such water penetrableartificial surfaces which serves 'to hold them away from the underlyingdeck in order to provide a drainage space for water beneath the outer 1walking or playing surface.

= and drawings in which:

FIG. 1 shows the drainage net of the invention combined with anoverlying sheet material,

FIG. 2 is a cross section through the assembly of FIG.

FIG. 3 is a cross section taken along the line 33 of FIG. 2,

FIG. 4 is a plan view of the drainage net of FIG. 2,

FIG. 5 shows one layout for the drainage net on a sloped deck, 7

FIGS. 6 and 7 are modifications of the drainage net of FIG. 2 showing awalking surface incorporated therein, and

FIGS. 8-13 show modifications of the drainage net of the invention. FIG.1 shows a deck 10 which has a sloped upper surface 12 and a coveringwaterproof sheet of polyethylene 14. As used throughout this applicationand inthe claims the term deck means any substrate or surface upon whichwater may tend to stand or from which water tends to run off such astamped earth, concrete, wooden platforms, and the like whether the sameare used (either indoors or outdoors) for patios, around swimming pools,balconies, tennis courts, playing fields, basement recreation roomfloors, laundry room floors, and the like. Further, as used herein,reference to the upper sloped surface of the deck refers to the uppersurface 12 of such a deck as above defined, or the upper surface of thecovering waterproof sheet 14 if one is present, whichever is applicablein a particular instance. In all of such instances quick drainage ofwater from the upper surface 12 is desirable and, accordingly, the uppersurface is sloped to suitable gutters or drains where the water isaccumulated and conveyed away from the deck. In many of theseapplications the deck is covered with a water penetrable sheet materialsuch as indoor-outdoor carpeting, perforated hardboa'rd, perforatedplywood, artificial turf, and the like which tends to hold the water inits openings and interstices after a rain or after being hosedorotherwise supplied with water. Under such circumstances much ofthewater does not adequately drain from the surface 12 of the deck 10and tends to lie stagnant making the surface unusable for walking orother like use.

As shown in FIG. 1 applicant providesfor drainage by means of a drainagenet 20. As more specifically shown in FIG. 1, the upper surface 12 ofthe deck 10 is covered with a polyethylene sheet 14 which prevents waterfrom soaking through and into the deck 10 when the deck is waterabsorptive as with tamped earth. Over the sheet 14 is placed thedrainage net 20 of this invention, and over the drainage net 20 isplaced the artificial surface 16 which may be, as indicated above, anyone of a number of materials. While the polyethylene sheet 14 is shownin FIGS. 1, 2', and 3, it is to be understood that its use is notrequired in all instances since it merely serves to make the upperslopedsurface of the deck 10 water impermeable.

The net 20 comprises at least two sets of strands I8 and 22. The net20is preferablyan extruded plastic net of any one of a number ofextrudable plastic materials well known to the extrusion art includingparticularly polypropylene. The net 20 is preferably of the typeproduced by the apparatus shown in the US. Pat. No. 3,252,181 in whichthe set of strands 18 can'be extruded parallel to each other and can beextruded at substantially a right angle to the set of strands 22 whichare also parallelto each other. By extrusionin this manner the number ofstrands, their dimension, and their relationships to each other may becontrolled within relatively wide limits.

As shown in the drawings the extruded plastic net 20 has one set ofparallel plastic strands 18 of greater height (see FIG. 2) than thecrossing set of strands 22. As shown in FIG. 4, the intersections of theset of strands l8 and the set of strands 22 form joints 24 integral withthe strands forming the joints and of the same material.

The net 20 has an upper surface 26 which as shown in FIGS. 1, 2, and 3supports the covering sheet material 16 which is water penetrable. Thestrands 18 extend downwardly into contact with the polyethylene sheet14, although, as indicated above, on some surfaces the polyethylenesheet 14 may be eliminated and the strands 18 may then bear directlyupon the upper surface 12 of the deck 10.

- As best shown in FIGS. 2 and 3 the set of strands 22 is not verticallyas deep as the set of strands 18 and accordingly spaces 30 are providedbeneath the plane of the upper surface 26 of the net through whichspaces 30 water may run down the sloped upper surface 12 (or thepolyethylene sheet 14 thereon) to suitable drains provided therefor.Accordingly, when water is supplied either by rain, by hosing, or byother means to the water penetrable surface 16 it will pass therethroughand downwardly into the spaces 30 where it will flow along the uppersurface of the deck 10 to suitably located drains.

Sets of strands 18, which are parallel, are normally arranged parallelto the slope of the upper surface 12 of the deck 10 as shownschematically in FIG. 5. As shown in FIG. 5 in plan view the uppersurface 12 of the deck 10 is sloped in the direction of the arrows 28and the first section 32 of the net 20 is arranged with its strands 18parallel to the direction of slope as indicated by the arrows 28.However, as further shown in FIG. 5, there may be occasions when it isdesirable to arrange the set of strands 18 of the net 20 at an angle tothe slope. As shown at 34 there are sections of the net 20 having theirstrands 18 at a substantial angle to the direction of slope as indicatedby the arrows 28. This angularity permits the water to be channeledtoward a drain 36 from a much larger area of sloped surface 12. For easeof illustration the cross strands 22 of the net 20 are not shown in FIG.5 and no covering sheet 16 is shown.

i It has been found that while the strands 18 are quite dense thefactthat the strands 22 bridge between the strands 18 provides someadditional resiliency to the walking surface thus adding to the comfortof the net 20 as a walking and playing surface particularly when thesame is used without the covering water penetrable sheet 16, althoughsimilar enhanced resiliency is also demonstrated when such covering 16is utilized. It is theorized, but not known, that when the weight doesnot bear directly upon a strand 18 but between strands 18, the crossstrands may bend downward, rocking the adjacent strands 18 and givingsome cushioning effect.

. While reference has been made above to the construction in which thenet 20 has lying thereover a water penetrable sheet 16 such as, forexample, an indoor-outdoor carpet, it is possible to treat the uppersurface 26 of the net 20 (whether made up of the tops of one set ofstrands or a plurality of sets of strands) with a suitable frictionsurface so that the upper surface 26 of the net 20 may itself be used asthe walking surface or playing surface for the area under consideration.As shown in FIG. 6 the upper surface 126 is provided with a frictionproducing material such as sand 127 indicated by the stippling in FIG.6. The sand may be embedded in the upper surface 126 of the net bysoftening the net under heat and applying the sand with slight pressurewhile the upper surface 126 is so softened.

Alternatively, the upper surface 226 as shown in FIG. 7 may be providedwith a pattern of embossing such as shown at 227 by means of a hotembossing roll or the like. The sand 127 and the embossing 227 of FIGS.6 and 7 respectively can provide a friction surface for walking or otherlike use directly upon the upper surface of the net thus eliminating theneed for the overlying water penetrable sheet 16. Ideally, such afriction surface is best provided when at least two sets of strands havetheir upper surfaces in a common .plane to.

provide the upper surface 26 of the net as shown in FIGS. 2 and 3. Inthis way considerable area can be presented for walking while stillproviding considerable area for water to penetrate downwardly into thedrainage spaces 30.

As shown in FIGS. 2 and 3 the upper surfaces of the strands 22 as wellas the upper surfaces of the strands 18 lie in a common plane thusforming the upper surface 26 of the net 20. This provides for anexcellent supporting surface for the overlying water penetrable sheetmaterial 16 and eliminates any tendency for the same to sag down intothe spaces between the set of strands 18. Such an arrangement alsoprovides a better surface 26 upon which to walk directly without theneed for a covering sheet 16. FIGS. 8 and 9, however, show variations ofthe net 20 in which the upper surface of the net does not have the setsof all strands coplanar on the upper side. As shown in FIG. 8 a net 20is illustrated having strands of one set 18' extending in one directionand strands 22' extending in the other direction, the strands 18 beinghigher than the strands 22'. In this instance the upper surface of thenet 20' as indicated at 26 comprises only the upper surfaces of thestrands 18'. Also, in this instance all of the strands 18 and 22' bearupon the underlying upper surface 12' of the deck. While thismodification is not preferred due to the fact that the strands 22 willblock water to the extent of their height, such an arrangement willpermit drainage in the space 30'above the strands 22'.

FIG. 9 shows a net 20" in which the cross strands 22' are centrallylocated vertically with respect to the thickness of the higher strands18". This arrangement permits for adequate drainage, but like themodification of FIG. 8, does not provide as much support as the uppersurface 26" (26' in FIG. 8) of the net for supporting an overlying waterpenetrable sheet such as that shown at 16 in FIG. 1, or for providing awalking or playing surface. Accordingly, the construction of FIGS. 1, 2,3, and 4 is preferred.

Another'modification is shown in FIG. 9A in which the net 209 has oneset of parallel plastic strands 189 and, lying thereabove, a crossingset of strands 229. This arrangement provides an upper surface 269 whichmay be used directly for walking or other like purpose or may be used tosupport the overlying water penetrable sheet 16. In this arrangementspaces 309 are provided beneath the plane of the surface 269 throughwhich water may run off the sloped underlying surface. Again, while thsmodification (FIG. 9A) provides adequate drainage, it does not provideas much support for an overlying water penetrable sheet such as 16, orfor providing a suitable walking or playing surface directly on theupper surface of the net.

FIG. 10 shows a modification in which the strands 181 and the strands221 are substantially of the same thickness but in which the joints 241formed'integrally therewith have protruding on one side thereofprojections or bumps 40. The projections or bumps 40 serve to raise theupper surface 261 of the net above the underlying slope to providedrainage space 301 for water. These projections 40 are readily providedduring the extrusion of the net. The modification of FIG. 10 providesthe least restriction to water flow of any of the modificationspreviously mentioned but cannot guide the runoff as can the nets 20,20', 20", or 209.

In FIG. 11 the net 202 is shown as comprising one set of parallelstrands 182 and another set of strands 222 at substantially right anglesthereto. Corrugations 50 are provided in the net 202 again to permitdrainage in the space 302 beneath the upper surface 262 of the net. Sucha corrugated net as shown at 202 also provides for enhanced resiliencywhen walking upon the upper sur face 262 or a water penetrable sheet(such as sheet 16) lying thereupon.

A variation of the net of FIG. 11 is shown in FIG. 12 wherein a net 203is shown having strands 183 in one direction and strands 223 in theother direction. In this instance the corrugations 503 are more widelyspaced and are directed in only one direction as compared with the netof FIG. ill. The net 203 of FIG. 12 provides a more continuous uppersurface 263 upon which to walk or upon which to place a water penetrablesheet such as shown at 16 in FIG. 1.

The corrugations of the nets of FIGS. 11 and 12 may readily be providedby molding or embossing the net after formation.

FIG. 13 shows a plan view of a variation of drainage net 204, which nethas strands 184 running in one direction and strands 224 running in theother direction. The net 204 has its strands sinuous but parallel as contrasted to the net of FIG. 1 in which the parallel strands l8 and theparallel strands 22 are substantially straight. By means of the sinuousshape'of the strands 184 and 224 of FIG. 13 the rate of flow of thewater of the underlying sloped surface may be somewhat controlled toavoid great gushes and consequent erosion.

While the preferred net, as indicated above, is a plastic extruded netmade in accordance with the disclosure in US. Pat. No. 3,252,181, otherplastic extrusion means are known including the process and apparatusdisclosed in US. Pat. No. 2,919,467, which produce a variation of thenet in which the openings thereof are diamond-shaped or hexagonal ratherthan rectangular. Such net, having diamond-shaped or hexagonal-shaped orother. shapedopenings therethrough may also be used, it only beingnecessary that the strands are dimensioned and arranged in such fashionas to provide suitable drainage space beneath the upper surface thereof.Other means of producing the net can also be utilized including variousweaves whereby the strands 18 are woven to the strands 20 provided,again, the strands are so dimensioned as to provide the requisitedrainage spaces. However, weaving of strands of. adequate strength tosupport the weight necessary in this application is generally difficultbecause of the thickness and stiffness of the strands. Additionally,while it is preferred that the entire net be of plastic material asindicated above, the strands 22 could be of wire or natural fibersembedded in the plastic strands 18.

I claim:

' 1. The combination comprising a deck, said deck having an upper slopedsurface to permit runoff of water, a net over said deck, said net havingan upper surface, said net including means extending into contact withsaid sloped upper surface of said deck for main taining runoff spacebeneath the plane of the upper surface of said net, substantially all ofthe spaces within said net being open, and a water penetrable sheetmaterial overlying said net.

2. The'combination of claim 1 in which said water penetrable sheet is acarpet.

of sets of plastic strands, said sets of strands defining openingstherebetween, substantially all of said openings being free ofobstruction to the runoff of water, said net having an upper surface,said net including means extending into contact with said sloped surfaceof said deck for maintaining runofi space beneath the plane of the uppersurface of said net, and a water penetrable sheet material overlyingsaid net.

5. The combination of claim 4 in which said water penetrable sheet is acarpet.

6. The combination of claim 4 in which said sheet material is secured tosaid net. p

' 7. The combination comprising a deck, said deck having an upper slopedsurface to permit runoff of water, a net over said deck, said net havingan upper surface, said net including a plurality of sets of strands, thestrands of one of said nets being parallel plastic strands extendinginto contact with said sloped upper surface of said deck for maintainingrunoff space beneath the plane of the upper surface of said net, theparallel strands of said one set being arranged generally downward ofthe slope of said sloped surface to provide with said surface channelsfor water runoff, substantially all of the spaces within said net beingopen, and the strands of another set being arranged at an angle to thestrands of said one set and intersecting the strands thereof to maintainthe strands of said one set in spaced parallel relationship.

8. The combination comprising a deck, said deck having an upper slopedsurface to permit runoff of water, a net over said upper sloped surface,said net having a plurality of sets of plastic strands, the strands ofone set intersecting the strands of another set to form joints at saidintersections integral with the strands forming the joint, the uppersurface of the strands of said one set and of the strands of said otherset being substantially in a common plane, the lower surface of thestrands of said one set being in engagement with said upper slopedsurface of said deck and thereby supporting said net, the strands ofsaid one set also being arranged generally downward of the slope of saiddeck to form with said deck channels for runoff of water, and the lowersurface of the strands of said other set being spaced above said uppersloped surface of said deck whereby water may run off said upper slopedsurface of said deck.

9. The combination of claim 8 in which the strands forming one of saidsets are parallel.

10'. The combination of claim 8 in which the strands of said one setintersect the strands of said other set at substantially a right angle.

,'UNITED STATES PATENT OFFICE I CERTIFICATE OF CORRECTION Patent No. 5 aa 180 v Dated March 5 a 97 Ronald L. Larsen Inventor(s) It is certifiedthat error appears in the above-identified patent and that said LettersPatent are hereby corrected as shown below:

Under Notice:

"The portion of the term of this patent subsequent to y 5, 1990 has beendisc1aimed"" should read -I'he portion of the term of this patentsubsequent to January 5, 1990 has been disc1aimed--- Signed and sealedthis 2nd day of July 1974.

(SEAL) Attest:

EDWARD M. FLETCHERJR. Y C.MARSHALL DANN Attesting Officer Commissionerof Patents FORM PO-10SO (IO-69) USCOMM'DC 60376-P69 .5. GOVERNMENTPRINTING OFFICE: I969 0-366-334

1. The combination comprising a deck, said deck having an upper slopedsurface to permit runoff of water, a net over said deck, said net havingan upper surface, said net including means extending into contact withsaid sloped upper surface of said deck for maintaining runoff spacebeneath the plane of the upper surface of said net, substantially all ofthe spaces within said net being open, and a water penetrable sheetmaterial overlying said net.
 2. The combination of claim 1 in which saidwater penetrable sheet is a carpet.
 3. The combination of claim 1 inwhich said sheet material is secured to said net.
 4. The combinationcomprising a deck, said deck having an upper sloped surface to permitrunoff of water, a net over said deck, said net including a plurality ofsets of plastic strands, said sets of strands defining openingstherebetween, substantially all of said openings being free ofobstruction to the runoff of water, said net having an upper surface,said net including means extending into contact with said sloped surfaceof said deck for maintaining runoff space beneath the plane of the uppersurface of said net, and a water penetrable sheet material overlyingsaid net.
 5. The combination of claim 4 in which said water penetrablesheet is a carpet.
 6. The combination of claim 4 in which said sheetmaterial is secured to said net.
 7. The combination comprising a deck,said deck having an upper sloped surface to permit runoff of water, anet over said deck, said net having an upper surface, said net includinga plurality of sets of strands, the strands of one of said nets beingparallel plastic strands extending into contact with said sloped uppersurface of said deck for maintaining runoff space beneath the plane ofthe upper surface of said net, the parallel strands of said one setbeing arranged generally downward of the slope of said sloped surface toprovide with said surface channels for water runoff, substantially allof the spaces within said net being open, and the strands of another setbeing arranged at an angle to the strands of said one set andintersecting the strands thereof to maintain the strands of said one setin spaced parallel relationship.
 8. The combination comprising a deck,said deck having an upper sloped surface to permit runoff of water, anet over said upper sloped surface, said net having a plurality of setsof plastic strands, the strands of one set intersecting the strands ofanother set to form joints at said intersections integral with thestrands forming the joint, the upper surface of the strands of said oneset and of the strands of said other set being substantially in a commonplane, the lower surface of the strands of said one set being inengagement with said upper sloped surface of said deck and therebysupporting said net, the strands of said one set also being arrangedgenerally downward of the slope of said deck to form with said deckchannels for runoff of water, and the lower surface of the strands ofsaid other set being spaced above said upper sloped surface of said deckwhereby water may run off said upper sloped surface of said deck.
 9. Thecombination of claim 8 in which the strands forming one of said sets areparallel.
 10. The combination of claim 8 in which the strands of saidone set intersect the strands of said other set at substantially a rightangle.